Fire resistant barrier

ABSTRACT

A fire resistant assembly, which may include a first layer having a lumen therein, a second layer adjacent the first layer, a first structural member disposed between the first and second layers, and a box having a cavity defined by a wall, a first opening in the wall, a second opening in the wall, a panel having a panel opening fastened to the box about the second opening, and a fixture installed in the cavity and having conduit extending through the second opening and the panel opening.

This application is a continuation application of U.S. application Ser.No. 11/142,568 filed Jun. 1, 2005.

FIELD OF THE INVENTION

The invention relates to a fire barrier having a recess for a device.More particularly, the invention relates to a recessed box installed ina building for use with maintaining a minimum fire endurance of abuilding surface.

BACKGROUND OF THE INVENTION

Typically, a surface of a building such as a floor or a ceiling providesa fire barrier. A fire barrier resists the spread of a fire through itby providing a resistance to flammability, a resistance to heattransmission, and sufficient structural integrity to resist decomposingwhen exposed to heat or flames. The effectiveness of a fire barrier isoften rated by exposure to a fire of specified and increasing intensityand a rating is a period of time, typically in hours during which thefire barrier is effective. When an aperture is made in one of these firebarriers, the effectiveness of the fire barrier is decreaseddramatically. Often it is nonetheless desirable to create an aperture ina fire barrier, for example, to install recessed lighting or a floordrain. To restore the fire barrier and maintain an effective minimumresistance to fire, a construction worker will typically build a box ofgypsum board and install it around the recessed fixture proximate theaperture created in the fire barrier. The construction of this box is atime-consuming task and provides no mechanism to ascertain to whatdegree the effectiveness of the fire barrier is restored. Moreover, manyfixtures have large conduits such as pipes or cable servicing them.Constructing a box that provides egress for these conduits whilemaintaining integrity as a fire barrier is often a time-consuming andchancy process. It is also frequently difficult to install a fixturesuch as a box light into a fire box that is only slightly larger.

SUMMARY OF THE INVENTION

One embodiment pertains to a fire resistant box to maintain theintegrity of a fire barrier in a building, while permitting the easyinstallation of a recessed fixture such as a light. The box may be madefrom steel or other suitable material and may have a flange forconvenient mounting to structural members such as ceiling joists or wallstuds. The box has a first opening through which the fixture may bemounted and a second opening which provides access to provide service tothe fixture. The second opening has a first larger size for use wheninstalling the box and the fixture into the box and a reduced size forallowing conduit such as electrical cable through the box wall whilemaintaining the integrity of the fire barrier. The second opening may bereduced in size by installing a panel on the box. In one embodiment,shifting the location of the panel may shift the location of the reducedstate second opening. Another contemplated embodiment permits the use ofthe fire resistant box in a hanging ceiling.

The above summary of some embodiments is not intended to describe eachdisclosed embodiment or every implementation of the present invention.The figures and detailed description which follow more particularlyexemplify these embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention may be more completely understood in consideration of thefollowing detailed description of various embodiments of the inventionin connection with the accompanying drawings in which:

FIG. 1 is a perspective diagrammatic exploded view of a box 100 forproviding fire resistance according to the invention;

FIG. 2 is a perspective diagrammatic view of box 200 for providing fireresistance according to the invention;

FIG. 3 is a cross-sectional diagrammatic view of a box in a fire barrier300; and

FIG. 4 is a cross-sectional diagrammatic view of a box in a fire barrier400.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

Reference is now made to the figures, in which like element numbersrefer to like elements throughout. FIG. 1 is a perspective view of a box100, which includes a wall 104 defining cavity 102. Flange 108 isdisposed proximate to an opening below through which an electricaldevice may be installed. It is to be understood that, while wall 104 isshown in FIG. 1 to be comprised of five flat surfaces and the opening,any shape defined by a cavity and having an opening may be suitable. Forexample, a cylinder open at one end may be suitable. As another example,the box depicted tapers slightly away from the flange; boxes which donot taper are also contemplated. Flange 108 provides a generally planarsurface for convenient mounting of the box in a fire barrier. Flange 108may include holes 110 for use with fasteners such as screws.

Wall 104 includes an additional opening 112 for providing service to afixture installed in cavity 102. Opening 116 is generally significantlylarger than may be required simply to pass conduit through. Opening 116may be large enough to install a ballast to a light fixture or may belarge enough to work on a fixture installed in cavity 102. Opening 112is covered by a panel 114. Panel 114 includes a panel opening 116 andmay include holes 118 for the installation of fasteners such asself-tapping screws. Panel 114 and opening 112 are configured in thisembodiment as covering two faces of wall 104. Other configurations, forexample a flat panel covering only one face, are contemplated. Panel 114may be installed over opening 112 and may be wide enough to coveropening 112 and to be installed in a preferred position. For example,panel 114 may be positioned more to one side but still cover opening 112so that panel opening 116 may be installed in a preferred position.Panel opening 116 may be just large enough to pass conduit through ormay be larger, for example to make it easier to grab conduit and pass itthrough. Panel opening 116 and opening 112 may be preformed or may bepunch-outs.

Refer to FIG. 2, which is a perspective view of box 200. Box 200 has awall 104 defined by a cavity but lacks a flange like flange 108 of theprevious embodiment. This configuration may be suitable for use in afire barrier where fastening the fire barrier to a structural memberwith nails or screws is not necessary or possible. For example, box 200may be used in a drop ceiling fire barrier. Of course, box 200 may stillbe fastened to another part of the fire barrier if desired. Wires orother suitable fastening members may be used. Box 200 includes anopening 112, which in this view is covered by panel 114 having anopening 116 therethrough.

Boxes 100 and 200 are made from a fire-resistant material such as steel.In one embodiment, a box is made from 24-gauge galvanized stainlesssteel. The box should be impervious to air where an opening as describedabove is not designed into the box. This may be accomplished during themanufacturing process. For example, if the faces of the box are weldedtogether, the weld may run the length of the seam. The box may also bemade using techniques such as stamping or hydroforming. Hydroforming isa technique where fluid pressure is used in the place of a punch to formmaterial. These latter techniques eliminate the need to seal seams, asno seams need be created during the manufacturing process.

Boxes 100 and 200 may also include an intumescent material. Anintumescent material is one that expands when in contact with fire orhigh heat but resists further deterioration. Many intumescent materialsexpand to eight or more times their original volume, producing a charwhich has a high fire resistance. Suitable intumescent materials may beprocured from 3M Corporation or other suitable supplier. The intumescentmaterial may seal gaps which are not sealed during the manufacturingprocess. For example, panel 114 may be coated with an intumescent paintor mastic or opening 116 may be filled with an intumescent gasket orputty, either before or after the conduit is passed through. In anotheralternative, opening 116 may be defined by a preinstalled intumescentgasket. Thus, if the box is exposed to fire, the intumescent materialwill expand to seal any gaps in the box, rendering the box impervious toair, smoke or flame flow.

FIG. 3 depicts fire barrier 300 having a box 100 installed therein. Firebarrier 300 is disposed in a building; suitable fire barriers maycomprise a floor and a ceiling, a ceiling and a roof, or a wall and awall. The fire barrier depicted in FIG. 3 comprises a ceiling and thefloor above. Fire barrier 300 may be comprised of a first layer 320having a lumen 322 therein, a second layer 324, and box 100 disposedtherebetween. Fire barrier 300 may also comprise structural members 325,such as joists, to which box 100 may be fastened using fasteners 326.Box 100 may also be fastened using other suitable means such as a hightemperature epoxy or spot welding.

Lumen 322 generally has a perimeter which may be smaller than theperimeter 230 of opening 106. Layer 320, therefore, may extend overflange 108. A device 327 may be disposed in lumen 322 and extend intocavity 102. This device may be any device installed in a fire barrier.Device 327 is a fluorescent fixture having wires 328 extendingtherefrom. Wires 328 extend through panel opening 116 and opening 112.Panel 114 has been attached to wall 104 using self-tapping screws 330.Of course, any suitable alternative to self-tapping screws may be used.For example, a high-temperature adhesive may be used. Installed betweenpanel 114 and box wall 104 is an intumescent gasket 332. There may be agap 334 between wall 104 and layer 324, and there may also be a gap 336between device 327 and wall 104. These gaps may enhance the fireresistance of fire barrier 200.

Layers 320 and 324 may comprise materials well known by those of skillin the art such a gypsum board, plywood, plaster or tile. Box 100 may becomprised of steel or other material having a melting temperature, forexample, above 1700° Fahrenheit such as ceramic. For example, box 100may be comprised of 24-gauge stainless steel. This material may begalvanized to resist corrosion. Wall 100 may have a perimeter wall 338that has an angle with the flange of greater than 90 degrees. This mayfacilitate stacking of boxes 100.

Fire barrier 200 may have an ASTM E-119 fire resistance rating of atleast 1 hour or at least 2 hours. The term “fire resistant” is hereindefined to refer to the ability of a structure to serve as a barrier tothe spread of fire. To serve as an effective barrier to the spread offire, a structure must exhibit the following characteristics. First, itmust not pass flame or hot gas from one side to the other. Second, thestructure must support the imposed design loads without structuralfailure or collapse. Third, the structure must resist the transmissionof heat so that the surface not exposed to the fire does not exceed thetemperature of 250° Fahrenheit. Fourth, the structure must withstandlateral impacts from falling debris. This is definition of the term“fire resistant” as understood by those of skill in the art.

A fire resistance rating of 1 hour exposes one side of the fire barrierto the following sequence of temperatures: 1000° F. for 5 minutes, 1400°F. for 15 minutes, 1550° F. for 30 minutes, and 1700° F. for 10 minutes.A fire resistance rating of 2 hours exposes the side of the fire barrierto 1700° F. for an additional 50 minutes and to a temperature of 1850°F. for 10 minutes. At no time during this test should the fire barrierpermit flames or hot gases through to the unexposed surface or allow theunexposed surface to exceed 250° F. This test was designed to simulatethe conditions to which a real fire might expose a fire barrier. Ofcourse, if this test is updated to reflect new understandings of theconditions of a fire, the fire barrier should be capable of a comparablerating under the new test.

Fire barrier 300 may be rated under ASTM E-119 or a comparable test. Theprocess of rating includes creating a fire barrier 300 and subjecting itto the test. A rated fire barrier 300 may permit installation of box 100in fire barriers governed by regulations. Certification of the ratingmay be included with box 100. Certification may also be affixed on box100, either on a label or permanently impressed into box 100 bystamping, etching or some similar process.

FIG. 4 is a cross-sectional diagrammatic side view of a fire barrier 400having box 200 installed therein. Figure barrier 400 is a drop ceiling.Thus, T-bars 402 are hung using wires 404 from a structural member 406.Structural member 406 may be a panel, a series of joists or othertypical structure. T-bars 402 form a grid of cavities. Typically, mostof these cavities are filled with ceiling panels 408. Some of thesecavities are often filled with fixtures such as fans or such as boxlight 410. Box 200 is installed over box light 410 to preserve theintegrity of the fire barrier. Box 200 has panel 114 attached to boxwall 104. Conduit 412 passes through opening 112 and panel opening 116.An intumescent putty 414 fills panel opening 116. Box 200 may rest on anedge 416 of box light 410 or may rest directly on T-bars 402. Box 200may be attached to structure member 406 with wires 404 if desired, ormay be attached to the structural member or T-bars using any suitablefastening member. There may be a gap 418 between box 200 and structuralmember 406 and another gap 420 between box wall 104 and box light 410.Box 200 may have a fire rating of one hour or more as installed in afire barrier 400, and certification thereof.

Numerous advantages of the invention covered by this document have beenset forth in the foregoing description. It will be understood, however,that this disclosure is, in many respects, only illustrative. Changesmay be made in details, particularly in matters of shape, size andarrangement of parts without exceeding the scope of the invention. Theinvention's scope is, of course, defined in the language in which theappended claims are expressed.

1. A fire resistant assembly, comprising: a first layer of a materialsuitable for use as a fire barrier having a lumen therein; a secondlayer of a material suitable for use as a fire barrier adjacent thefirst layer; a fire resistant box having a cavity defined by a pluralityof walls, a first opening in the plurality of walls having a firstperimeter, a second opening in the plurality of walls having a secondperimeter, a panel fastened over the second opening, the panel and atleast one of the plurality of walls forming a third opening having athird perimeter smaller than the second perimeter, the third openingbeing an opening through at least on of the walls and the panel; andwherein the box is disposed between the first layer and the second layerand wherein the first opening is disposed on the lumen of the firstlayer.
 2. The assembly of claim 1, wherein both the panel and at leastone of the plurality of walls defines the third perimeter.
 3. Theassembly of claim 2, wherein the panel defines all of the thirdperimeter.
 4. The assembly of claim 2, wherein the panel, prior tofastening, is adjustable relative to the box such that the third openingmay be in one of two or more possible positions.
 5. The assembly ofclaim 1, wherein the plurality of walls comprises a base section and aperimeter section joined at an edge, wherein the second opening isdisposed through the base section and the perimeter section and extendsthrough the edge.
 6. The assembly of claim 5 wherein the base sectionand the perimeter section form an angle of between about 90° and about135°.
 7. The assembly of claim 5 wherein the base section is flat. 8.The assembly of claim 7 wherein the perimeter section includes four flatwalls.
 9. The assembly of claim 8 wherein the perimeter section includesno more than four flat walls.
 10. The assembly of claim 1, wherein thebox further comprises a plurality of fasteners joining at least one ofthe plurality of walls to the panel.
 11. The assembly of claim 10,wherein the fasteners are self-tapping screws.
 12. The assembly of claim1, further comprising an intumescent material sealing the panel to thebox.
 13. The assembly of claim 12, wherein the intumescent material is aputty.
 14. The assembly of claim 1, wherein the box comprises steel. 15.The assembly of claim 14, wherein the box comprises 24-gauge galvanizedstainless steel.
 16. The assembly of claim 15, wherein the electricaldevice is a rectangular light fixture.
 17. The assembly of claim 1,having an American Society for Testing and Materials (ASTM) E-119 fireendurance rating of at least 1 hour.
 18. The assembly of claim 1,further comprising an electrical device disposed through the firstopening and at least partially in the cavity.
 19. The assembly of claim1, wherein the box further comprises a flange proximate the firstopening.
 20. The assembly of claim 1, further comprising a suspensionwire and wherein the second layer comprises a ceiling tile.
 21. Theassembly of claim 20, further comprising a tie between the first layerand the box.
 22. The assembly of claim 21, wherein the tie is a wire.23. A method of providing a fire barrier in a building, the stepscomprising: providing a first layer of a material suitable for use as afire barrier; providing a lumen in the first layer; providing a secondlayer of a material suitable for use as a fire barrier; providing a boxof a material suitable for use as a fire barrier, the box having acavity defined by a plurality of walls, a first opening in at least oneof the plurality of walls, and a second opening in at least one of theplurality of walls such that the opening in the box covers the lumen inthe first layer, disposing a device in the lumen and extending into thecavity of the box; disposing a conduit through the second opening; andattaching a panel to at least one of the plurality of walls of the boxto at least partially close the second opening, wherein the box isdisposed between the first layer and the second layer and wherein thefirst opening is disposed on the lumen of the first layer.
 24. Themethod of claim 23, wherein the step of attaching the panel to theplurality of walls of the box includes the step of providing an openingin the panel such that when the panel is attached to the box, an openingthrough at least one of the plurality of walls smaller than the secondopening is formed.
 25. The method of claim 24, further comprising thestep of sealing any gap between the conduit and the second opening. 26.The method of claim 23, further comprising the step of sealing a jointbetween the box and the panel.
 27. The method of claim 26, wherein thestep of sealing the joint includes the step of providing intumescentmaterial to seal the joint.
 28. The method of claim 26, wherein thejoint is substantially airtight after it has been sealed.
 29. The methodof claim 28, wherein the second layer is a suspending ceiling, whereinthe light fixture is designed to drop into a suspended ceiling cell, andwherein the box is designed to drop into the suspended ceiling cellaround the light fixture.
 30. The method of claim 23, wherein the stepof attaching the panel includes the step of screwing the panel to thebox.
 31. The method of claim 23, wherein the step of attaching the panelincludes the step of selecting a position among two positions for theinstallation of the panel relative to the box.
 32. The method of claim23, further comprising the step of providing a light fixture.